1996 AUDI A4 coolant

19-16

Installing
Installation is the reverse of removal, noting the
following:

- Clean sealing surfaces of both housings.

- Replace gasket and O-ring.

- Insert T-head bolt into coolant pump bore.

- Mount bracket for generator, power steering pump and viscous fan with
coolant pump on cylinder block and tighten bolts in numerical
sequence.
1 - M8 x 70 bolt
2 - M8 x 110 bolt
3 - M8 x 50 bolt
4 - M8 x 90 bolt
5 - M8 x 70 bolt
6 - M8 x 100 bolt
- Install viscous fan Page 13
-14
, Fig. 1
.
- Install ribbed belt Page 13
-17
.
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19-17

Note:
When installing ribbed belt, check for correct
seating on belt pulley.

- Install V-belt Page 13
-18
.

- Fill up with coolant Page 19
-6 .

WARNING!

The cooling system is pressurized when the
engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and
open carefully to relieve system pressure
slowly.

CAUTION!

Be sure the ignition is switched OFF. Failure
to do so may damage the Engine Control
Module (ECM).

- Switch ignition off and reconnect battery Ground
(GND) strap.

- After connecting battery, enter anti-theft code for
radio.

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19-19

Component
Tightening
torques
Generator to bracket for
generator, power steering pump
and viscous fan
M8 25 Nm (18 ft
lb)
M10 40 Nm (30 ft
lb)
Belt pulley to coolant pump 25 Nm (18 ft
lb)
Viscous fan to bearing 45 Nm (33 ft
lb)
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19-20

Coolant thermostat, removing, installing
and checking


Removing

- Drain coolant Page 19
-4 .

Installing
WARNING!
The cooling system is pressurized when the engine is warm. When
opening the expansion tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and open carefully to relieve
system pressure slowly.
Tightening torque - Remove bolts -4-, remove connector -3-, O-ring -2- and coolant
thermostat -1-.
- Clean and/or smooth O-ring sealing surface.
- Install coolant thermostat.
- Fill up with coolant Page 19
-6 .
Component
Tightening torque
Connector to pump housing 10 Nm (7 ft lb)
Pa
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19-21

Coolant thermostat, checking

- Warm thermostat in hot water bath.

Starts to
open Fully open
Stroke
approx. 87 C
(189 F)
approx. 102 C
1)
(216 F)
min. 8
mm
(0.315 in.)
1) Cannot be tested.
Pa
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g system com
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g and installin
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19-22

Coolant line (lower), removing and
installing


Removing

- Drain coolant Page 19
-4 .

- Remove intake air duct between intake manifold
and charge air cooler.

- Remove hose -4- to oil cooler at lower coolant line -2-.
- Remove hose -5- to heater core at lower coolant line.
- Remove lower coolant line from hose -1- at coolant pump.
- Unbolt lower coolant line from oil filter bracket -3-.
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19-23

Installing
Installation is the reverse of removal, noting the
following:

- Fill with coolant Page 19
-6 .

WARNING!

The cooling system is pressurized when the
engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and
open carefully to relieve system pressure
slowly.
Pa
ge 27 of 34 Coolin
g system com
ponents, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.19.1

19-24

Radiator, removing and installing


Special tools and equipment
VAG1306 drip tray

Removing

- Remove front bumper.

Repair Manual, Body Exterior, Repair Group
63


WARNING!
The cooling system is pressurized when the engine is warm. When
opening the expansion tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and open carefully to relieve
system pressure slowly. - Unbolt cooling pipe for power steering hydraulic oil (arrows).
- Place VAG1306 drip tray underneath engine.
- Open coolant expansion tank cap.
Pa
ge 28 of 34 Coolin
g system com
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g and installin
g
11/18/2002 htt
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yp
e=re
pair&id=AUDI.B5.GE02.19.1